Production Process
Our production process follows strict high standards, with each step carefully controlled to ensure that our sofas and soft play products achieve excellence in safety, comfort, and durability. Below is a detailed breakdown of our process.
Meet Our Factory Director
Behind every soft module we make is a leader who truly understands the responsibility ofmaking products for children.
Mr. Hu, our Factory Director and co-founder, has been in factory management since 2005and has spent the past 16 years specializing in soft foam furniture for kids.
Known for his rigorous standards and calm discipline, Mr. Hu ensures our workshop runs withprecision, consistency, and above all - safety.
Manufacturing Workflow
Preparation of Materials for Examination
Purpose:
Ensure design drawings, styles, fabrics, trims, and foam types are fully aligned with inventory.
Key Actions:
- Sample/Drawing Confirmation
- Fabric Order
- Trimming Arrival Inspection
- Foam Specification Preparation
Responsibilities:
PMC + Development Department + Warehouse
Fabric Cutting (Automatic/manual)
Purpose:
Cut fabric according to pattern drawings
Equipment and Tools:
Automatic fabric cutting machine + manual electric shears.
Responsibilities:
Precisely allow for seam allowances at joints, numbering and categorizing.
Sewing & Fabric Assembly
Purpose:
Sewing fabric into modular pieces to create a removable or fixed cover.
Process:
- Jointing
- Sewing
- Corner wrapping
- Zip/Velcro application
Key Points:
Even stitching, neat edge banding, and accurate logo placement
Foam Cutting (CNC cutting)
Purpose:
Cut large foam sheets into specific sizes and shapes according to product structural drawings.
Key Equipment:
CNC foam cutting machine, high-speed cutter, foam stacking system.
Precision Requirements:
±2mm, burr-free edges
Responsibilities:
PMC + Development Department + Warehouse
Foam Insertion & Shaping
Purpose:
Assemble the foam and fabric cover and complete the shaping process.
Key Actions:
Press the foam into the fabric bag with manual pressure.Locally adjust the bend and align the seam allowance.
Inspection Points:
Full appearance, natural curves, and no bubbles or wrinkles.
Compression Packing
Purpose:
Use vacuum compression or automated compression systems to reduce volume and facilitate export.
Process:
- Fold
- Pack
- Vacuum evacuation
- Heat sealing
Volume reduction: 60%-70%
Key Points:
Start compression 3-5 days before shipping to minimize compression time. The shorter the compression time, the better the rebound effect.
Label & Packing
Purpose:
Apply barcodes and warning labels according to customer requirements and perform standard packaging.
Requirements:
Apply barcodes by SKU and batch number.Package items according to the packaging diagram (multiple items must be separated).
Standard:
Outer box must be waterproof/compression-resistant, with smooth sealing tape and a neat appearance.
Warehousing
Purpose:
Orderly storage of finished goods, supporting stocking, container consolidation, and customer-specified shipping plans.
System Operation:
- ERP Registration
- Warehouse Partitioning
- Schedule shipments by delivery date
Key Points:
Supports mixed SKU loading, direct shipping, and overseas warehouse delivery.
Warehousing
Purpose:
Orderly storage of finished goods, supporting stocking, container consolidation, and customer-specified shipping plans.
Methods supported:
- FULL (40HQ)
- LCL (mixed container load)
- Palletizing + film wrapping + loading
Key Points:
Timeline control + simultaneous preparation of customs clearance documents
Key Equipment
Smart Compression Packaging System
Save 60% Volume. Cut Shipping Costs. Boost Efficiency.
Why is compression packaging important?
Children's soft goods are bulky, lightweight, and yet take up space, making them a challenge in cross-border shipping. Tenderplayful, leveraging years of technological expertise, has developed a highly efficient compression and packaging system that helps customers save 75-82% of shipping volume without sacrificing product quality, significantly reducing unit logistics costs.
How do we achieve compression?
A variety of compression methods are available to suit different product structures:
Vacuum compression:Suitable for children's sofas, small soft toys, etc.
Roller compression:Suitable for modular sofas, soft toys, ball pool mats, etc.
Compressed packaging format
High-density vacuum-packed PE bags ensure neat and controlled packaging.
Automatic sealing ensures no bulging during transportation.
The packaging is labeled "Please wait 48 hours" for end-user convenience.
Improved loading efficiency
Taking a 40HQ container as an example, traditional sofa products can be loaded with about 120-150 pieces, but after Tenderplayful compression, it can be loaded with more than 200 pieces, greatly improving the profit margin of a single container.
User safety + customer experience
Compressed products recover within 48 hours after unpacking, with a rebound rate of over 95%. We include a restoration card and unpacking instructions with each product to ensure easy use for end customers.
Frequently Asked Questions
Customization Process
We offer customizable styles, fabrics, and foam options, including classic or personalized designs, various materials, and multiple foam choices for comfort.
Design & Samples
Customers can provide their own designs or request assistance from our design team. We offer samples for approval, which are generally charged, with the fee partially credited if a bulk order is confirmed. Design modifications are allowed during the process. Sample delivery typically takes 7-10 business days.
Delivery & Shipping
Customized products typically have a delivery time of 15 to 30 business days, depending on complexity and quantity. To ensure on-time delivery, we provide real-time updates and address potential delays proactively. We use professional packaging and collaborate with trusted logistics companies to ensure the products are safely delivered without damage.
Quality Assurance
We guarantee the quality of customized products through strict adherence to international standards and thorough quality checks at every production stage. If any quality issues arise, we offer after-sales services such as replacements or repairs. Our quality inspection process includes material testing and functionality checks, and we ensure product durability by using high-quality materials and providing care instructions.
Custom Styles, Fabrics, and Foam
We offer customizable styles, fabrics, and foam options, including classic or personalized designs, various materials, and multiple foam choices for comfort.
Logistics Efficiency | From Factory to the World
Proximity to Ningbo Port + Smart Packaging = Fast, Cost-Efficient Global Shipping
Proximity to Ningbo Port + Smart Packaging = Fast, Cost-Efficient Global Shipping
Our factory is located in Ninghai, eastern China, just a 1.5-hour drive from the world-class container hub of Ningbo Port, offering convenient access to land-port intermodal transport.
Fast dispatch, same-day container pickup, and flexible arrangements for LCL/FCL shipments are our daily rhythm of efficiency.
Flexible and diverse shipping methods
We support a variety of shipping options to meet diverse customer needs:
Full Container Load (FCL) / Less Than Container Load (LCL)
Multiple SKU palletizing
Connect with overseas warehouses or direct shipping platforms for transit
Multiple SKU palletizingConnect with overseas warehouses or direct shipping platforms for transit
Combined with our compression packaging system, the actual loading capacity of each container can be increased by up to 4-5 times, effectively reducing unit logistics costs and helping you gain higher profit margins in global channel competition.
Delivery time and tracking management
Daily production scheduling + fast loading responseArrival at port within 2 hours
Provide complete delivery documentation, including loading diagrams, packing lists, and tracking numbers
Capturing Moments of Trust, Connecting Clients Worldwide
At Tenderplay, every handshake, every visit, and every photo tells a story — a story of mutual trust, shared values, and lasting partnerships. From Europe to North America, Asia to Oceania, we’ve had the honor of welcoming clients from all over the world to our factory. These captured moments are more than just pictures — they are the proof of genuine collaboration and growing friendships across borders.